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Reliability Technician

Date: Nov 30, 2022

Location: Monroe, MI, US, 48161

Company: Gerdau

This position is open to domestic candidates only. 

BASIC FUNCTION:

 

The Reliability Technician provides coordination and support for implementing and sustaining the Asset Reliability Processes (ARP) to improve asset health and equipment reliability which increases technical availability and reduces maintenance costs by:

  1. Finding the initial point of equipment failure allowing a planned and scheduled process for repair;
  2. Creating Failure Modes Evaluation Analysis (FMEA) and predictive matrix using historical and current equipment data;
  3. Developing maintenance plans and tasks that ensure a proactive process through using the Computer Maintenance Management Systems (CMMS);
  4. Submitting requests for predictive work using a formal, systematic, analytical approach;
  5. Participating in the development of Annual Action Plans;
  6. Training maintenance and operations personnel in basic predictive practices;
  7. Conducting routine predictive audits including: maintenance plans and task evaluations, cycles times, results versus delays analyses and visibility tours as assigned;
  8. Ensuring that safety rules and requirements are being followed in all work areas.

 

DIMENSIONS:

 

This position performs condition based maintenance surveys of electrical, mechanical and process equipment utilizing Predictive Methods and equipment for vibration analysis, thermographic scans, airbourne ultrasound, specialized motor testing equipment (MCE) and NDT (nondestructive testing)  methods following mill requirements and documented inspection tasks.  

 

NATURE AND SCOPE:

 

This position is primarily responsible for planning, coordinating, completing and documenting predictive condition monitoring of mill assets. Providing technical assistance and maintenance expertise to the assigned Gerdau mill location.  The Reliability Technician reports directly to the Reliability Engineer IV or V.

 

This position will maximize the reliability of equipment using a formal, systematic/analytical approach to trouble-shooting, failure analysis, predictive/preventive maintenance and design improvements.  The incumbent will participate in, and lead, special projects in maintenance activities that will improve the reliability of the equipment, optimize maintenance costs and reduce equipment downtime.

 

Qualifications for this position include a working knowledge of heavy manufacturing, with at least 5 years hands-on-experience in maintenance as an instrument technician, master mechanic or technician or equivalent status.  Incumbent must possess a high school diploma or equivalent and must have general knowledge of a thermographer, electric motor test technician and vibration analyst in a heavy industrial environment.  A technical college diploma in electrical or mechanical discipline is desired but not required.

 

The successful applicant will possess a strong motivation to implement new technologies, champion predictive maintenance efforts, solve complex problems, project management skills and  computer skills in order to improve reliability of mill operations.  This position will assist on most inspections and will perform repairs on deficiencies found via PdM tools whenever feasible.

 

This position will be responsible for maintaining all test reports, standard operating procedures in maintenance, and equipment reliability databases such as SAP and other maintenance related software systems.  Equipment routes will be developed with all predictive technologies in conjunction with Reliability Engineer and mill operating and maintenance departments.

 

Due to close contact with operating management and personnel, outside contractors and vendors, this position requires the ability to effectively communicate with a variety of personalities and interests to achieve optimal results.  The incumbent must manage the interests of all parties in creating and modifying work procedures and equipment without compromise to safety, quality, cost or environment.

 

The incumbent will work within the Gerdau Business System (GBS) and SAP or other CMMS system to monitor and manage performance.  Key indicators will be developed in support of ARP assessment.  This position will also participate, organize and  conduct training programs for the maintenance personnel regarding new testing equipment, new operating equipment, software, methodologies and procedures.

 

Due to the nature of manufacturing operations the incumbent may be required to be on-call and must have high availability depending on the requirement of the operation or project being managed.

 

Responsible for staying abreast of current technology and recommending changes to effect continual improvement of production processes.  The incumbent should also possess a broad knowledge of maintenance concepts and techniques. 

 

The incumbent will be required to manage other special projects as assigned.

 

  • Participate in major failure incident investigations in area of responsibility.
  • Conduct routine safety and preventive maintenance activities including inspections, audits, employee contacts and visibility tours.
  • Ensure that safety rules and requirements are being followed in all work areas.
  • Maintain compliance with visual management standards.

 

 

 

PRINCIPAL ACCOUNTABILITIES:

 

  1. Perform condition based maintenance surveys on plant equipment using vibration, thermography, MCE, visual inspections, airbourne ultrasound and other techniques/technologies as appropriate.
  2. Prepare written reports to document inspections and recommendations for preventive actions.
  3. Be available for overtime work, both scheduled and unscheduled.
  4. Maintain test equipment and tools in a clean, safe and functional condition at all times.
  5. Practice good housekeeping (5S) in work area.
  6. Adhere to safety and environmental rules and policies.
  7. Acquire and maintain minimum Level II certification in vibration analysis, thermography and airbourne ultrasound along with advanced MCE certificate within two years of starting training.
  8. Coordinate and manage minimum PdM work order backlog for area of responsibility.
  9. Monitor and report Key Performance Indicators (KPIs) to support ARP assessment and improvement.
  10. Participate in major failure incident investigations in area of responsibility as required.
  11. Ensure timely completion of preventative maintenance and predictive-based work orders within specifications, and in compliance with appropriate rules and regulations.
  12. Develop planning and scheduling for all predictive and some preventive based work orders. Coordinate, support and complete predictive maintenance practices in the area assigned within the plant.
  13. Assist in the development of the use of predictive based technologies and preventive work orders to maximize equipment reliability.  Implement and establish priorities for predictive maintenance.
  14. Develop PdM routes and perform predictive services that facilitate continuous improvement through new condition monitoring and innovative approaches to production processes.
  15. Insure timely completion of preventive maintenance and predictive based work orders within specifications and compliance with appropriate rules and regulations affecting the area. Responsible for any modifications to the preventive maintenance program that might reduce maintenance cost and downtime.
  16. Responsible for auditing the established preventive maintenance program and updating as required to maximize effectiveness
  17. Provide technical expertise to solve department problems.

 

Benefits:

Medical and Prescription

Dental

Vision

Health & Dependent Care (Flexible Spending Account)

401K

Basic Life/Accidental Life Insurance

Health Advocate Services

Employee Assistance Program

Tuition Reimbursement Program

 

 

Gerdau believes in equal employment opportunity related to all employees and applicants for employment.  It is the policy of Gerdau that there will be no discrimination against any employee or applicant for employment on the basis of race, religion, color, national origin, citizenship, marital status, sex, age, sexual orientation, genetic information, gender identity, veteran status, disability, or other legally protected status.  All external applicants must be legally eligible to immediately work in the country of hire without current or future sponsorship.

 

If you are vision-impaired or have some other disability under the Americans with Disabilities Act or a similar law, and you wish to discuss potential accommodations related to applying for employment at Gerdau, please contact our Talent Acquisition Team at (866) 788-2798 or recruiting@gerdau.com.

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Nearest Major Market: Monroe
Nearest Secondary Market: Detroit